Modular Corrugated Surface Waveguide for mm-Wave Borehole Drilling
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Solution Overview
Problem
Existing waveguides for electromagnetic waves in drilling operations are expensive, prone to manufacturing errors, and inefficient, leading to inventory waste and operational downtime, particularly in non-conventional drilling techniques like millimeter wave drilling.
Innovation Solution
A system comprising a mm wave emitter, enclosure, and components like mirrors, frequency sensors, arc detectors, and cooled wire grids to manage electromagnetic wave transmission efficiently, with corrugated features and miter bends to maintain wave mode, and integrated protection and monitoring systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If corrugated waveguides are formed in single lengths of tubes, then transmission efficiency of electromagnetic waves is enhanced, but manufacturing cost increases, manufacturing complexity increases, and manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The waveguide system is divided into multiple discrete components including corrugated sections, smooth sections, miter bends, and flanged joints. Each component can be manufactured separately using standard fabrication processes, then assembled into a complete waveguide system. This segmentation allows each component to be optimized independently while maintaining overall transmission efficiency.
Solution Approach 2:
Flanged joints serve as intermediary connection elements between separate waveguide components. These flanges provide precise alignment and secure mechanical connection while maintaining electromagnetic continuity. The intermediary flanged joints enable modular assembly without compromising the transmission efficiency that would otherwise require a single continuous corrugated structure.
2Loss of energy
If corrugated waveguides are formed in single lengths of tubes, then transmission efficiency of electromagnetic waves is enhanced, but manufacturing precision deteriorates due to accumulated errors
Solution Approach 1:
The waveguide is segmented into multiple precision-manufactured components with standardized tolerances. Each segment (corrugated section, smooth section, bend) is manufactured to controlled precision specifications, preventing error accumulation that would occur in a single long-tube fabrication process. The segmented approach allows quality control at each manufacturing stage.
Solution Approach 2:
The design transitions from a single continuous corrugated tube to a hybrid structure with both corrugated and smooth sections, connected by precisely engineered flanged joints. This parameter change in the structural configuration allows maintenance of transmission efficiency through corrugated sections while achieving manufacturing precision through modular assembly of controlled-length components.
3Loss of energy
If specialized materials and equipment are used for manufacturing corrugated waveguides, then transmission efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The waveguide system is segmented into components that can be manufactured using conventional materials and equipment. Standard metallic materials and common fabrication techniques (bending, flanging, bolting) are sufficient for each component, eliminating the need for specialized manufacturing processes while maintaining transmission efficiency through proper geometric design of the corrugated sections.
Solution Approach 2:
The design uses replicated standard components (flanged joints, connection interfaces) that can be manufactured using established tooling and processes. Rather than requiring unique specialized equipment for each waveguide feature, the system employs repeated use of standard connection geometries and materials that are well-established in conventional manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances transmission efficiency, reduces costs, and minimizes operational downtime by using individually manufactured components with precise corrugation features, providing integrated protection and monitoring in hazardous environments.
Implementation Method 1
The corrugation are features configured to maintain the electromagnetic wave in the first mode as the electromagnetic wave propagates through the first set of waveguides and/or the one or more miter bends
Implementation Method 2
A cooled wire grid configured to direct electromagnetic radiation in the first mode reflected from the borehole away from the mm wave emitter
Implementation Method 3
A millimeter (mm) wave emitter configured to emit an electromagnetic wave... to form a borehole of a well... through thermal drilling and/or millimeter wave drilling
Data Source
AI summary
An enclosure is configured to receive an electromagnetic wave from a mm wave emitter by a first waveguide positioned between the mm wave emitter and the enclosure. The enclosure includes one or more components configured to manage transmission of the electromagnetic wave in the first mode to a second waveguide positioned relative to a borehole of a well to be formed by the electromagnetic wave transmitted through the second waveguide. The components can include a first port at which a gas is received, a focusing mirror, a frequency sensor, a power measurement sensor, an arc detector, a cooled wire grid, a load cell provided on an exterior surface of the enclosure, or a barrier window. Related apparatus, systems, techniques, and articles are also described.